Flexible, arc resistant, fluid repellant, high temperature and abrasion resistant, circumferentially continuous, seamless textile sleeve and method of construction thereof

This invention relates generally to textile sleeves for protecting elongate members, and more particularly to flexible, circumferentially continuous, seamless textile sleeves having arc resistant, abrasion resistant, heat resistant and fluid repellent properties.

It is known to contain and protect elongate members, such as wires and wire harnesses, for example, in circumferentially continuous, tubular textile sleeves to provide protection to the cables, wires, and hoses. However, these sleeves typically have multiple layers, with each of the layers being specifically provided for a different type of protection. Although the aforementioned multilayer sleeves may provide suitable protection against various environmental conditions, unfortunately they are bulky, having a thick, multilayered wall with different types of yarns being provided in each layer, thereby requiring an increased volume of space, and further, they tend to be relatively heavy and exhibit low flexibility. Further yet, having to include multiple layers can prove problematic in some applications, particularly applications requiring routing cables, wires or hoses through tight, winding areas, as well as applications having weight restrictions, such as aircraft and aerospace applications, for example.

One aspect of the invention provides a textile sleeve for routing and protecting an elongate member. The textile sleeve includes a circumferentially continuous, seamless wall. The circumferentially continuous, seamless s wall includes a textile layer having an outer surface and an opposite inner surface bounding an enclosed cavity extending lengthwise along a central longitudinal axis between opposite open ends. The textile layer is formed of yarns interlaced with one another, wherein at least some of the yarns include multifilaments resistant to heat and monofilaments resistant to heat, and a silicone-based coating adhered to the outer surface of the textile layer.

In accordance with another aspect of the invention, the yarns can including warp yarns extending generally parallel to the central longitudinal axis and weft yarns extending generally transversely to the central longitudinal axis, with the warp yarns being woven with the weft yarns.

In accordance with another aspect of the invention, the warp yarns can be provided entirely from multifilaments resistant to heat and the weft yarns can be provided including monofilaments resistant to heat.

In accordance with another aspect of the invention, the weft yarns can be provided including monofilaments resistant to heat and multifilaments resistant to heat.

In accordance with another aspect of the invention, the multifilaments resistant to heat can be provided as meta-aramid.

In accordance with another aspect of the invention, the warp multifilaments resistant to heat can be provided having a denier between about 100-3000 and the weft multifilaments resistant to heat can be provided having a denier between about 50-1000.

In accordance with another aspect of the invention, the monofilaments resistant to heat can be provided having a diameter between about 0.1-0.5 mm.

In accordance with another aspect of the invention, the monofilaments resistant to heat can be provided as PEEK.

In accordance with another aspect of the invention, the silicone-based coating can include at least one, or both of a flame retardant and a heat stabilizer.

In accordance with another aspect of the invention, the silicone-based coating has a thickness between about 0.1-3.0 mm.

In accordance with another aspect of the invention, the textile layer is circumferentially continuous and seamless.

In accordance with another aspect of the invention, the textile layer has opposite edges extending lengthwise between the opposite open ends, with the opposite edges being in overlapped relation with one another, with a seam formed between the overlapped edges, wherein the silicone-based coating is circumferentially continuous and seamless to close off the seam between the overlapped opposite edges.

In accordance with another aspect of the invention, a method of constructing a wrappable sleeve for routing and protecting an elongate member from arcing, exposure to abrasion, thermal conditions including high heat and fire, fluid (water/fuel) ingress, and other environmental conditions, such as contamination, and to protect against fluid absorption into a wall of the wrappable sleeve, is provided. The method includes interlacing heat-resistant yarn to form a textile layer having an outer surface and an inner surface bounding a cavity extending lengthwise along a central longitudinal axis between opposite open ends. Further, bonding a silicone-based coating on an outer surface of the textile layer such that the silicone-based coating is circumferentially continuous and seamless along the length of the textile layer.

In accordance with another aspect of the invention, the method can further include interlacing the yarns with one another in a weaving process, a knitting process, or a braiding process. If woven, the method can further include weaving the yarns including warp yarns extending generally parallel to the central longitudinal axis, with the warp yarns being provided entirely as multifilaments resistant to heat, and weft yarns extending generally transversely to the warp yarns, with the weft yarns including monofilaments resistant to heat.

In accordance with another aspect of the invention, the method can further include providing the weft yarns including both monofilaments and multifilaments resistant to heat.

In accordance with another aspect of the invention, the method can further include providing the warp multifilaments having a denier between about 100-3000 and providing the weft multifilaments having a denier between about 50-1000.

In accordance with another aspect of the invention, the method can further include providing the weft monofilaments having a diameter between about 0.1-0.5 mm.

In accordance with another aspect of the invention, the method can further include weaving the warp yarns and the weft yarns in one of a plain, twill, basket, or satin weave pattern.

In accordance with another aspect of the invention, the method can further include weaving the weft monofilaments and multifilaments in alternating relation with one another along the entirety of the length of the wall.

In accordance with another aspect of the invention, the method can further include providing the silicone-based coating having a thickness between about 0.1-3.0 mm.

In accordance with another aspect of the invention, the method can further include providing the silicone-based coating including at least one of a flame retardant and a heat stabilizer.

In accordance with another aspect of the invention, the method can further include forming the textile layer as a circumferentially continuous and seamless layer.

In accordance with another aspect of the invention, the method can further include forming the textile layer having opposite edges extending lengthwise between the opposite open ends, and wrapping the opposite edges being in overlapped relation with one another.

Referring in more detail to the drawings,show a schematic representation of a circumferentially continuous, seamless textile sleeve, referred to hereafter as sleeve,, respectively, constructed in accordance with different aspects of the invention. The sleeve,has a flexible, circumferentially continuous, seamless elongate wall,, respectively, for routing and protecting an elongate member(s), such as a cable, wires, and pipe, for example, from exposure to arcing (electrical flow path through an air gap from a cable or wire to another conductor, such that energy of a cable or wire is contained inside the wall,, thereby preventing the release of energy from the sleeve,), abrasion, thermal conditions including high heat and fire, fluid absorption and ingress, e.g. water, oil, fuel, and the like, and other environmental conditions, such as contamination. The wall,can be constructed having any suitable size, including length and diameter. The wall,has an inner surfaceand an opposite outer surface. The wall,has an inner, interlaced textile layer,, respectively, formed of yarnsinterlaced with one another in one of a woven (), knit (), or braided () fashion, wherein a least some of the yarnsinclude multifilamentsresistant to heat, and monofilamentsresistant to heat, thereby allowing the sleeve,to withstand exposure to high heat and fire for a predetermined amount of time, including up to about 2 hours or more, while protecting the elongate memberagainst heat damage. A silicone-based coatingis adhered to the outer surfaceof the interlaced textile layer,, shown as being adhered to the entirety of the outer surface, thereby forming a circumferentially continuous, seamless silicone-based coatingabout the interlaced textile layer,. As such, the silicone-based coatingenhances the aforementioned levels of protection to the elongate member, particularly with regard to the prevention of arc and fluid absorption/ingress. The interlaced textile layeris formed as a circumferentially continuous, seamless layer, while the interlaced textile layerhas opposite edges,extending lengthwise between opposite open ends,. The opposite edges,are wrapped in overlapped relation with one another with a seam formed between the overlapped edges,. With silicone-based coatingbeing circumferentially continuous and seamless, it closes off the seam between the overlapped opposite edges,, thereby rendering the wallcircumferentially continuous and seamless.

The silicone-based coatingis a fluid impervious coating, thereby being impervious to water, fuel (e.g. kerosene), oil, and the like, to render the wall,fluid impervious as well as fluid repellant. As such, fluid is prevented from being absorbed by the interlaced layer,, thus, preventing water, fuel and the like from compromising the ability of the sleeve,to provide the desired levels of protection. The silicone-based coatingcan include at least one or both of a flame retardant and a heat stabilizer, and can be provided having a thickness between about 0.1-3.0 mm, thereby contributing to the wall,having a narrow profile, thereby enhancing the flexibility and ability to be routed in relatively small, tight spaces.

The interlaced yarns, in a preferred embodiment of, are woven, including warp yarnsextending generally parallel to the central longitudinal axisand weft yarnsextending generally transversely to the central longitudinal axis. The warp yarnscan be woven with the weft yarnsin any desired weave pattern, including a pain weave, twill weave, satin weave or basket weave, for example, with the plain weave pattern being preferred to provide a smooth, stable and uniform protection pattern, with the smoothness facilitating bonding of the silicone-base coatingto the outer surface. The warp yarnscan be provided entirely from the multifilaments, with the multifilamentsbeing resistant to heat (high temperature resistant) and the weft yarns can be provided including the monofilaments, with the monofilamentsalso being resistant to heat (high temperature resistant), while also having high abrasion resistance. Further yet, if desired to provide the wallas being self-wrapping, the monofilamentscan be provided as being heat-settable, thereby be able to be heat-set to impart a heat-formed bias in the wallto maintain the opposite edges,in overlapping relation with one another, absent an externally applied force sufficient to overcome the internal bias. Of course, the silicone-based coatingacts to seal and close off the seam formed between the opposite edges,, thereby providing the sleeveas being circumferentially continuous and seamless along its length. The weft yarnscan further include the multifilamentsbeing resistant to heat, with the weft monofilamentsand weft multifilamentsbeing provided in any desired ratio, and in one presently preferred embodiment, the weft monofilamentsand weft multifilamentscan be woven in alternating relation with one another in a 1:1 ratio.

The warp multifilaments,can be provided as meta-aramid having a denier between about 100-3000 tex, and the weft multifilaments,can be provided having a denier between about 50-1000 tex. The weft monofilaments,can be provided as PEEK having a diameter between about 0.1-0.5 mm. With the weft multifilaments,having a reduced effective diameter than the warp multifilaments,, an increased weave tightness and density can be achieved to provide enhance protection to the elongate member.

In accordance with another aspect of the disclosure, with reference to, the textile layer,can be knitted or braided with the aforementioned multifilamentsand monofilaments. It is to be recognized that any desired combination of the multifilamentsand/or monofilamentscan be used to form the knitted or braided interlaced yarns.

In accordance with another aspect of the invention, a method of constructing a textile sleeve,is provided. The method includes interlacing heat-resistant yarnto form a textile layer,having an outer surfaceand an inner surfacebounding a cavityextending lengthwise along a central longitudinal axisbetween opposite open ends,. Further, bonding a silicone-based coatingon the outer surfaceof the textile layer,such that the silicone-based coatingis circumferentially continuous and seamless along the length of the textile layer,

The method can further include interlacing the yarnswith one another in a weaving process, a knitting process, or a braiding process. If woven, the method can further include weaving the yarns including warp yarnsextending generally parallel to the central longitudinal axis, with the warp yarnsbeing provided entirely as multifilamentsresistant to heat, and weft yarnsextending generally transversely to the warp yarns, with the weft yarnsincluding monofilamentsresistant to heat.

In accordance with another aspect, the weft yarnscan further include monofilamentsand multifilamentsresistant to heat.

The method can further include providing the warp multifilaments,having a denier between about 100-3000 tex and providing the weft multifilaments,having a denier between about 50-1000 tex.

The method can further include providing the weft monofilamentshaving a diameter between about 0.1-0.5 mm.

Further yet, the method can include weaving the warp yarnsand the weft yarnsin one of a plain, twill, basket, or satin weave pattern.

The method can further include weaving the weft monofilamentsand weft multifilamentsin alternating relation with one another along the entirety of the length of the wall, such that the monofilamentsand weft multifilamentsare provided in a 1:1 ratio.

The method can further include providing the silicone-based coatinghaving a thickness between about 0.1-3.0 mm, and in one exemplary embodiment, a thickness between about 0.1-1.00 mm.

The method can further include providing the silicone-based coatingincluding at least one of a flame retardant and a heat stabilizer, thereby allowing the sleeve to withstand exposure to high heat and fire for a predetermined amount of time, including up to about 2 hours, while protecting the elongate member therein against damage.

The method can further include forming the textile layeras a circumferentially continuous and seamless layer.

The method can further include forming the textile layerhaving opposite edges,extending lengthwise between the opposite open ends,, and wrapping the opposite edges,being in overlapped relation with one another.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is contemplated that all features of all claims and of all embodiments can be combined with each other, so long as such combinations would not contradict one another. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.